Robotic package unloading machine

Abstract

This invention presents a design for a robotic unloading system that could be used to unload packages from containers. In the basic configuration, a robotic manipulator is coupled with a vision or sensor system and powered conveyor belt. The robot and vision system are used to identify packages and determine presence and orientation. A conveyor belt is positioned in close proximity to the package being removed. The robot and EOAT are used to move the package only a short distance to where the conveyor belt catches the product and carries it away. The greatly simplifies the system design since the robot does not need the precision to securely lift and carry the package. The robot only needs to move the package onto the conveyor that is actively and advantageously positioned for each package removal action. The robot and conveyor work together to simplify the unloading process. The robot is only used to move product onto the conveyor.

1 . A robotic package unloading system for unloading uniform as well as non-uniform and non-structured bulk packages, comprising: 
 a container for holding at least one package;    a robotic manipulator, wherein an end-of-arm tool is used to grip said package;    a takeaway conveyor for moving said package,    conveying means which is actively positioned to engage the package at one end and to be connected to said takeaway conveyor at second end;    an image/sensor to identify and locate said package in said container; and    a computer to control and process said robotic manipulator, said articulating belt and said image/sensor.    
     
     
         2 . The robotic package loading system as described in  claim 1 , wherein said conveying means is an articulating belt  
     
     
         3 . The robotic package unloading system as described in claim wherein said conveying means is a slide.  
     
     
         4 . The robotic package unloading system as described in  claim 1 , further comprising: 
 a carriage for mounting said robotic manipulator;    a carriage lift frame along which the carriage can move up and down; and    a lift mechanism to position said carriage at a correct height for unloading said package.    
     
     
         5 . The robotic package unloading system as described in  claim 1 , wherein said container is selected from the group consisting of a pallet, a bin and a case.  
     
     
         6 . The robotic package unloading system as described in  claim 1 , wherein said package is selected from the group consisting of uniform and non-uniform and non-structured bulk.  
     
     
         7 . The robotic package unloading system as described in  claim 1 , further comprising a safety enclosure to protect surrounding personnel.  
     
     
         8 . The robotic package unloading system as described in  claim 1 , wherein said computer is used to process an algorithm to interpret the image sensor data and determine the location of packages for unloading.  
     
     
         9 . The robotic package unloading system as described in  claim 8 , wherein the computer provides the robot manipulator with position and path data so that the robot manipulator grips the package with a variety of preprogrammed strategies.  
     
     
         10 . A method of unloading uniform as well as non-uniform and non-structured bulk packages from a container, comprising the steps of: 
 holding a package in a container;    gripping said package with a robotic manipulator having an end-of-arm tool;    moving said package with a short takeaway conveyor belt;    connecting said carriage with said takeaway belt;    identifying and locating said package in said container with an image sensor; and    controlling and processing said robotic manipulator, said lift mechanism and said image sensor with a computer.    
     
     
         11 . The method of unloading as described in  claim 10 , further comprising after the step of gripping the steps of: 
 mounting said robotic manipulator in a carriage frame so that the robotic manipulator can move up and down; and    lifting said carriage to position said carriage at a correct height for unloading said package with a lift mechanism.    
     
     
         12 . The method of unloading as described in  claim 10 , wherein said package is pulled outwards until the package makes contact with the takeaway conveying belt, and once the package makes contact with the takeaway belt, the robot manipulator releases the package and let the package be carried away to the articulating belt, which in turn carries the package to the fixed takeaway conveyor.  
     
     
         13 . The method of unloading as described in  claim 11 , further comprising a step of lowering said carriage after completing unloading all packages on a single layer until new packages are sensed by said image sensor.  
     
     
         14 . The method of unloading as described in  claim 13 , further comprising a step of repeating said steps until all layers of the container are unloaded and the container is empty.  
     
     
         15 . The method of unloading as described in  claim 13 , further comprising a step of positioning a new container by an operator into positioning for automatic unloading system.